3,500 Pound Keeperless
Cargo Hook Kit
For The
Airbus Helicopters AS350 Series
and EC130B4
Part Number 200-261-00
Owner's Manual
Owner's Manual Number 120-094-00
Revision 10
November 28, 2016
13915 NW 3rd Court Vancouver Washington 98685 USA
Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883
www.OnboardSystems.com
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RECORD OF REVISIONS
Revision
Date
Page(s)
Reason for Revision
1
11/15/00
2
7/23/02
3
9/17/02
Title, 4-3
Factory address change.
4
10/23/02
1-1
Added Model B3 to list.
5
10/10/03
6
2/12/04
1-1
7
09/05/06
Section 4 & 3-1
Original issue.
1-1, 2-2, 2-4, and 2-5 Added 290-744-00 Adapter to BOM and
installation instruction, fig 2.4 and 2.5 graphic
change.
1-1, 1-2, 2-1, and 4-1 528-023-01 cargo hook configuration change
Reference Service Bulletin 159-011-00
TOC, Section 1, 2-2,
2-5, & Section 3
Added EC130B4 to applicability
Updated cargo hook kit maintenance
information.
Added Warnings, Cautions and Notes section.
Updated warnings, cautions and notes format.
8
08/11/09
Section 2, Page 2-3
Added caution notes and revised Figure 2-2.
9
03/08/10
Section 2
Clarified manual release cable installation
instructions. Added notes allowing bumper
P/N 290-773-00 and manual release cable P/N
268-024-02 to be used with this kit.
10
11/28/16
All
Revised manual release cable installation
instructions, added reference to Service
Bulletin 159-039-00 and Bumper Kit 232-15500, general updates throughout.
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iii
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CONTENTS
Section 1 General Information
Introduction, 1-1
Safety Labels, 1-1
Bill of Materials, 1-2
Inspection, 1-2
Specifications, 1-3
Theory of Operation, 1-3
Section 2 Installation Instructions
Cargo Hook Removal, 2-1
Cargo Hook Installation, 2-1
Cargo Sling Installation, 2-1
Cargo Swing Installation, 2-4
Installation Check-Out, 2-8
Component Weights, 2-8
Cargo Hook Location, 2-8
Paper Work, 2-8
Section 3 Operation Instructions
Operating Procedures, 3-1
Cargo Hook Rigging, 3-2
Cargo Hook Loading, 3-3
Section 4 Maintenance
Inspection, 4-1
Instructions for Returning a System to the Factory, 4-1
Section 5 Certification
STC, 5-1
Canadian Approval, 5-3
EASA STC, 5-4
v
CONTENTS, continued
Figures
2-1 Sling Mount Cargo Hook Installation Assembly, 2-1
2-2 Manual Release Cable Rigging, 2-3
2-3 Swing Mount Cargo Hook Installation Assembly, 2-4
2-4 Loop Clamp Installation, 2-6
2-5 Swing Assembly Overview, 2-6
2-6 Un-Commanded Release From Incorrectly Secured Cable, 2-7
3-1 Cargo Hook Rigging Examples, 3-2
3-2 Cargo Hook Loading, 3-3
Tables
1-1
2-1
2-2
vi
Specifications, 1-2
Cargo Hook Connector, 2-3
Component Weights, 2-8
Section 1
General Information
Introduction
The 200-261-00 Cargo Hook Kit is approved as a replacement for the
following Cargo Hooks on the AS350B, AS350B1, AS350B2, AS350B3,
AS350BA, AS350D and EC130B4 Series. This applies to either the
swing or sling type systems for all models except the AS350B3 for which
it applies to the sling system only and the EC130B4 for which it applies to
the swing system only.
P/N
17149-1
14027-4
S1609-3
S1609-5
S1609-6
Manufacturer
Breeze-Eastern
Breeze-Eastern
Siren
Siren
Siren
Safety Labels
The following definitions apply to safety labels used in this manual.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Draws the reader’s attention to important or
unusual information not directly related to safety.
Used to address practices not related to personal
injury.
General Information
1-1
Bill of Materials
The following items are included with the Cargo Hook Kit, if shortages
are found contact the company from whom the system was purchased.
Part Number
120-094-00
121-005-00
122-005-00
123-002-00
290-403-00
290-744-00
410-131-00
510-042-00
510-252-00
510-257-00
512-010-00
528-023-01
Description
Owner’s Manual
RFMS
CMM, Cargo Hook
ICA Maintenance Manual
Hook to Manual Release Adapter
HK Manual Release Adapter
Electrical Connector
Washer
Jam Nut
Bolt
Cushioned Loop Clamp
3,500 Lb. Keeperless Cargo Hook
Quantity
1
1
1
1
1
1
1
2
1
2
2
1
Inspection
Inspect the cargo hook for evidence of damage, corrosion and security of
lock wire and fasteners. If damage is evident, do not use the unit until it
has been repaired.
1-2
General Information
Specifications
Table 1-1 Specifications (528-023-01 Cargo Hook)
Design load
Design ultimate strength
Electrical release capacity
Mechanical release capacity
Force required for mechanical
release at 3,500 lb.
Electrical requirements
Minimum release load
Unit weight
Mating electrical connector
3,500 lb. (1,580 kg.)
15,750 lb. (7,140 kg.)
8,750 lb. (3,970 kg.)
8,750 lb. (3,970 kg.)
8 lb. Max.(.600” travel)
22-32 VDC 6.9 - 10 amps
0 pounds
3.0 pounds (1.35 kg.)
PC06A8-2S SR
Theory of Operation
The primary elements of the Cargo Hook are the load beam, the internal
mechanism, and a DC solenoid. The load beam supports the load and is
latched through the internal mechanism. The DC solenoid and an external
manual release cable provide the means for unlatching the load beam.
The load is attached to the load beam by passing the cargo sling ring into
the throat of the load beam and pushing the ring against the upper portion
of the load beam throat, which will initiate the hook to close. In the closed
position, a latch engages the load beam and latches it in this position.
To release the load, the latch is disengaged from the load beam. With the
latch disengaged, the weight of the load causes the load beam to swing to
its open position, and the cargo sling slides off the load beam. The load
beam then remains in the open position awaiting the next load.
A load release can be initiated by three different methods. Normal release
is achieved by pilot actuation of the push-button switch in the cockpit.
When the push-button switch is pressed, it energizes the DC solenoid in
the Cargo Hook, and the solenoid opens the latch in the internal
mechanism. In an emergency, release can be achieved by operating a
mechanical release cable. The release cable operates the internal
mechanism of the Cargo Hook to unlatch the load beam. The load can also
be released by the actuation of a lever located on the side of the Cargo
Hook.
General Information
1-3
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Section 2
Installation Instructions
These procedures are provided for the benefit of experienced aircraft
maintenance facilities capable of carrying out the procedures. They must
not be attempted by those lacking the necessary expertise.
Cargo Hook Removal
Remove the old Cargo Hook from the aircraft by disconnecting the hook
from the load link (gauge shackle) and the manual and electrical release
cables.
Cargo Hook Installation
Cargo Sling Installation
Inspect the load link, universal joint and attaching hardware to insure
that they are in serviceable condition.
Attach the new Cargo Hook to the load link using the hardware supplied,
as illustrated below. The cargo hook load beam should point forward.
Figure 2-1 Sling Mount Cargo Hook Installation Assembly
AS 350 HARD POINT
AN WASHER
P/N 510-144-00
(AN 960-816L)
NAS WASHER
P/N 510-174-00
(NAS 1149F0663P)
MS COTTER PIN
P/N 510-178-00
(MS24665-302)
AN NUT
P/N 510-170-00
(AN 320-C6)
CARGO HOOK
Installation Instructions
AS 350 UNIVERSAL
AS 350 LOAD LINK
OR LOAD CELL
LOAD BOLT
P/N 290-332-00
AN WASHER
P/N 510-144-00
(AN 960-816L)
MANUAL RELEASE
SIDE OF HOOK
2-1
Cargo Hook Installation, continued
Cargo Sling Installation continued
Remove the manual release cover from the Cargo Hook.
It is NOT recommended to use an OEM release
cable with a barrel-style end fitting with this
Cargo Hook (see Service Bulletin 159-039-00).
If an acceptable OEM release cable is present (reference service bulletin
159-039-00) it may be used with the supplied adapter fitting P/N 290-40300 or P/N 290-744-00 to connect to the cargo hook, otherwise obtain
Onboard Systems Manual Release Cable P/N 268-024-02 for this
installation.
Thread the Manual Release Cable P/N 268-024-02 directly into the Cargo
Hook and place the cable ball end fitting into the hook fork fitting as
illustrated in Figure 2-2. Attach the other end of the manual release cable
to the OEM fixed release cable.
Move the manual release lever in the clockwise direction until it is against
the cam stop (this is readily felt as the lever moves relatively easily for
several degrees before encountering greater resistance). Measure the cable
ball end free play with the manual release lever in the cockpit in the nonrelease position. Adjust the manual release cable system to provide a
minimum of .125” (3.2 mm) of freeplay at the fork fitting as shown in
Figure 2-2.
Manual release cable rigging must be done with
the cargo hook in the closed and locked position.
2-2
Installation Instructions
Cargo Hook Installation, continued
Cargo Sling Installation continued
Figure 2-2 Manual Release Cable Rigging
manual release lever
manual release cable
fork
.125" min.
(3.2 mm)
cable ball end
Load beam must be
closed and locked
when rigging.
Re-install the manual release cover and torque the cover screws to 12-15
in-lbs. Safety wire the cover screws.
Reconnect the electrical release cable connector to the Cargo Hook.
Listed below is the pin out for the cargo hook connector.
Table 2-1 Cargo Hook Connector
Pin
Function
A
B
Ground
Power
The cargo hook is equipped with a suppression
diode that will be damaged if the cargo hook
electrical connection is reversed. Do not attach
the electrical connector until the polarity of the
aircraft connector is determined to be compatible
with the cargo hook connector listed in table 2-1.
Installation Instructions
2-3
Cargo Hook Installation, continued
Cargo Swing Installation
Inspect the swing assembly components to ensure that they are in
serviceable condition.
Attach the new cargo hook to the load link using the hardware supplied,
as illustrated below. The cargo hook load beam must point forward.
A cargo hook bumper (P/N 290-773-00) is
available which provides protection for the
electrical connector and manual release cable in
the swing installation. It must be installed with
Attach Bolt P/N 290-775-00 (replacing P/N 290332-00 in Figure 2-3). These components and the
washers, nut and cotter pin (shown below) are
available as Bumper Kit P/N 232-155-00. Refer
also to Service Bulletin 159-039-00.
Figure 2-3 Swing Mount Cargo Hook Installation Assembly
AS 350 Load Link
or Load Cell
Washer
P/N 510-174-00
(NAS 1149F0663P)
Washer
P/N 510-144-00
(AN960-816L)
Cargo hook
2-4
Manual release
lever side of hook.
Installation Instructions
Cargo Hook Installation continued
Cargo Swing Installation continued
Remove the manual release cover from the Cargo Hook.
It is NOT recommended to use an OEM manual
release cable with a barrel-style end fitting with
this Cargo Hook (see Service Bulletin 159-03900).
If an acceptable OEM release cable is present (reference service bulletin
159-039-00) it may be used with the supplied adapter fitting P/N 290403-00 or P/N 290-744-00 to connect to the cargo hook, otherwise
obtain Onboard Systems Manual Release Cable P/N 268-024-02 for this
installation.
Thread the Manual Release Cable P/N 268-024-02 directly into the
Cargo Hook and place the cable ball end fitting into the hook fork fitting
as illustrated in Figure 2-2. Attach the other end of the manual release
cable to the OEM fixed manual release cable (in the same manner as the
OEM manual release cable was installed).
Move the manual release lever in the clockwise direction until it is
against the cam stop (this is readily felt as the lever moves relatively
easily for several degrees before encountering greater resistance).
Measure the cable ball end free play with the manual release lever in the
cockpit in the non-release position. Adjust the manual release cable
system to provide a minimum of .125” (3.2 mm) of freeplay at the fork
fitting as shown in Figure 2-2.
Tighten the jam nut against the hook and secure with safety wire.
Reinstall the manual release cover and torque the cover screws to 12-15
in-lbs. Safety wire the cover screws.
Installation Instructions
2-5
Cargo Hook Installation continued
Cargo Swing Installation continued
Electrical Connection
If the hook removed was manufactured by Siren or if it was a BreezeEastern 14027-4 it will be necessary to replace the connector on the
electrical release cable with the one supplied with the Cargo Hook Kit. If
preferred a short adapter cable can be fabricated to connect the electrical
release cable to the hook. Connect the cargo hook electrical release cable
connector to the Cargo Hook and secure with safety wire.
See table 2-1 for connector pin out information
Loop Clamp Installation
Secure the cushioned loop clamps using the threaded holes, bolts and
washers provided as illustrated in Figure 2-4. Safety wire the bolts.
Figure 2-4 Loop Clamp Installation
Loop Clamps
P/N 512-010-00
Bolt P/N 510-257-00
Washer P/N 510-042-00
Attach the two elastic cords that were previously removed to the loop
clamps that are supplied with the Cargo Hook Kit. Refer to the illustration
below.
Figure 2-5 Swing Assembly Overview
2-6
Installation Instructions
Cargo Hook Installation, continued
Un-commanded cargo hook release will happen if
the manual release cable is improperly restrained.
The cables must not be the stops that prevent the
Cargo Hook from swinging freely in all
directions. If the Cargo Hook loads cause the
hook to strain against the manual release cable
the swaged end of the cable may separate
allowing the inner cable to activate the cargo
hook manual release mechanism. The result is an
un-commanded release. Ensure that no
combination of cyclic stick or cargo hook position
is restrained by the manual release cable.
Figure 2-6 Un-Commanded Release From Incorrectly Secured Cable
Installation Instructions
2-7
Installation Check-Out
After installation of the Cargo Hook, perform the following functional
checks.
1. Swing the installed Cargo Hook to ensure that the manual release cable
assembly and the electrical release cable have enough slack to allow
full swing of the suspension assembly without straining or damaging
the cables. The cables must not be the stops that prevent the Cargo
Hook from swinging freely in all directions. It may be necessary to
install bumper pads on the Swing to prevent the release cables from
being damaged.
2. With no load on the cargo hook load beam and pull the release lever in
the cockpit, the Cargo Hook must release. Reset the cargo hook load
beam.
3. Close the cargo hook release circuit breaker and position the battery
switch to the ON position. With no load on the cargo hook load beam,
depress the cargo hook electrical release button, the Cargo Hook must
release. Reset the cargo hook load beam.
4. See the Airbus Helicopters service instructions for your specific
helicopter model for additional installation instructions.
Component Weights
The weight of the Cargo Hook Kit components are listed below.
Table 2-2 Component Weights
Item
Weight
Cargo Hook
3.0 pounds (1.4 kgs)
Cargo Hook Location
See the Airbus Helicopters provided Flight Manual Supplement for
external load weight and balance data.
Paper Work
In the US, fill in FAA form 337 for the initial installation. This procedure
may vary in different countries. Make the appropriate aircraft log book
entry. Insert the Rotorcraft Flight Manual Supplement P/N 121-005-00
into the Rotorcraft Flight Manual.
2-8
Installation Instructions
Section 3
Operation Instructions
Operating Procedures
Prior to a flight involving external load operations perform the following.
1. Ensure that the Cargo Hook has been properly installed and that the
manual and electrical release cables do not limit the movement of the
hook.
2. Activate the electrical system and press the cargo hook release button to
ensure the cargo hook electrical release is operating correctly. The
mechanism should operate smoothly and the Cargo Hook should after
release. Return the load beam to its closed position by hand, if the
hook does not re-latch do not use the unit until the difficulty is
resolved.
The release solenoid is intended to be energized
only intermittently. Depressing the electrical
release button continuously in excess of 20 sec.
will cause the release solenoid to overheat,
possibly causing permanent damage.
3. Activate the manual release lever in the cockpit to test the cargo hook
manual release mechanism. The mechanism should operate smoothly
and the Cargo Hook must release. Return the load beam to its closed
position by hand, if the hook does not re-latch do not use the unit until
the difficulty is resolved.
See the Component Maintenance Manual 122-005-00 and the Airbus
Helicopters service instructions that cover the original Cargo Hook
installation for additional instructions.
Operation Instructions
3-1
Cargo Hook Rigging
Extreme care must be exercised when rigging a load to the Cargo Hook.
Steel load rings are recommended to provide consistent release performance
and resistance to fouling. Figure 3-1 shows the recommended rigging and
rigging to avoid, but is not intended to represent all rigging possibilities.
Some combinations of small primary rings and
large secondary rings could cause fouling during
release.
It is the responsibility of the operator to ensure the cargo hook will function
properly with each rigging.
Nylon type straps (or similar material) or rope
must not be used directly on the cargo hook load
beam. If nylon straps or rope must be used they
should be first attached to a steel primary ring.
Verify that the ring will freely slide off the load
beam when it is opened. Only the primary ring
should be in contact with the load beam.
Figure 3-1 Cargo Hook Rigging Examples
Recommended
Avoid
Primary Ring
Long Line
3-2
Operation Instructions
Cargo Hook Loading
The cargo hook can easily be loaded with one hand. A load is attached to
the hook by pushing the ring upward against the upper portion of the load
beam throat, as illustrated in Figure 3-2, until an internal latch engages the
load beam and latches it in the closed position.
Figure 3-2 Cargo Hook Loading
Operation Instructions
3-3
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Section 4
Maintenance
Refer to Component Maintenance Manual 122-005-00 for detailed
maintenance information specific to the Cargo Hook and ICA 123-002-00
for general maintenance of the cargo hook kit.
Instructions for Returning Equipment to the Factory
If an Onboard Systems product must be returned to the factory for any
reason (including returns, service, repairs, overhaul, etc) obtain an RMA
number before shipping your return.
An RMA number is required for all equipment
returns.

To obtain an RMA, please use one of the listed methods.
 Contact Technical Support by phone or e-mail
([email protected]).
 Generate an RMA number at our website:
http://www.onboardsystems.com/rma.php

After you have obtained the RMA number, please be sure to:

Package the component carefully to ensure safe transit.

Write the RMA number on the outside of the box or on the mailing
label.

Include the RMA number and reason for the return on your
purchase or work order.

Include your name, address, phone and fax number and email (as
applicable).

Return the components freight, cartage, insurance and customs
prepaid to:
Onboard Systems
13915 NW 3rd Court
Vancouver, Washington 98685
USA
Phone: 360-546-3072
Maintenance
4-1
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Section 5
Certification
STC
Certification
5-1
STC continued
5-2
Certification
Canadian Approval
Certification
5-3
EASA STC
5-4
Certification
EASA STC continued
Certification
5-5